Make laser marking versatile

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Flexible shooting with MATRIX X-SUPPORT and FLEXSTATION

Laser marking is mandatory in many industries: serial numbers, article codes, UDI, batch or traceability data. The laser can work with high precision — but only if the component is in a defined position every time.

And this is exactly where the bottleneck often occurs in practice: not the laser, but the recording.

When product portfolios grow, variants increase and geometries change, classic, component-specific nests scale poorly. They tie up budget, require space and extend set-up and start-up times.

In this article, we show two ways in which laser marking can be set up robustly and efficiently with a wide range of variants:

• manually, quickly and flexibly with MATRIX X-SUPPORT modules
• programmable and automatable with MATRIX FLEXSTATION and pallets

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Challenge: laser marking in a high-mix environment

In labeling practice, two worlds come together:

• The laser process is standardized and repeatable.
• Pick-up is often a mix of special parts, workarounds and experience.

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Typical symptoms when the intake does not grow with the variety of variants:

• Setup costs increase with every new geometry.
• Components must be manually aligned, underlaid or readjusted.
• Rejection risk is increasing (wrong position, wrong labeling area, focus position does not fit).
• Equipment inventory is growing (more nests, more storage, more handling).
• Changes to the component result in new hardware.

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The goal is therefore not “the perfect device for a part,” but scalable logic: a recording that adapts quickly to different geometries — while remaining reproducible.

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Approach: Two variants, one principle

Depending on the level of automation and quantity, there are two useful setup variants. Both follow the same principle: defined component position instead of trial and error.

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Version A: Manual laser marking with X-SUPPORT modules

The X-SUPPORT is designed for precise measurement and marking of small to medium-sized components — including laser marking; PEEK pins are optional for sensitive surfaces.

The idea: Instead of forcing a component into a fixed nest, the support is flexibly adapted to the geometry using pins. This allows the component position to be defined stably without making a separate image for each variant.

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Customer example: ZEPF MEDICAL INSTRUMENTS

In a user statement, ZEPF MEDICAL INSTRUMENTS describes a product portfolio of 15,000 articles — the variety of variants in the exciting geometries is correspondingly high. A solution was sought for the laser marking process that covered this diversity.

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When variant A is particularly suitable

• Many items/variants, but manual labeling (e.g. workstations, workshop, rework, spare parts production)
• Frequent product changes, low to medium quantities
• Objective: quick changes and stable component position — without building up equipment inventory

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Version B: Programmable holder for laser cells with FLEXSTATION and pallets

When laser marking is partially automated or fully automated (e.g. with workpiece carriers, handling or integrated stations), the requirements increase:

• Change must be even faster.
• Setups should be digitally documented and retrievable.
• The recording should be able to be derived from CAD instead of being set up manually.

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This is exactly where FLEXSTATION comes in: From CAD files to ready-to-use production in around 15 minutes — without retooling and without special devices.

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What does that mean in the caption

1. Using CAD data instead of redesigning a device
   FLEXSTATION is compatible with common formats such as STEP, IGES and DXF.
2. Automatically derive setup
   The software recognizes geometry, position and vertices and creates the setup.
3. Pallet principle for quick changes
   Setups can be transferred to standardized carriers/pallets. As a result, the laser process is not dependent on a single, component-specific nest. Changeovers between articles can be planned — including a clear allocation of “which recipe belongs to which part”.
4. Integration into the line
   The FLEXSTATION is ideal for connecting to PLC, CNC and robotics; there are also integrations via OPC UA, MQTT and REST API.

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effect in the laser process

• Less set-up time: Switching between articles can be planned and is faster (manually or automatically).
• Less special hardware: fewer component-specific nests, less storage and handling.
• Higher process reliability: Defined component position reduces incorrect markings and rework.
• Faster introduction of new variants: New articles can be set up using CAD data instead of waiting weeks for devices.
• Better scalability: High-mix can be managed without the tool landscape exploding.

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Quick check: Which variant is right for your laser process?

Variant A (X-SUPPORT) is often the quickest way to get started when the labeling is manual and the variety of variants is high.

Option B (FLEXSTATION + pallets) is particularly worthwhile if:

• changeover times are a bottleneck
• setups must be documented and reproducibly retrievable
• or the lettering is to be integrated into an automated line.

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Conclusion: The laser is precise — make the recording just as flexible

Laser marking only really scales well when the workpiece holder keeps up with the variety of variants.

With X-SUPPORT, high-mix lettering can be implemented quickly and robustly manually. With FLEXSTATION, the next step is possible: CAD-based, programmable setups and quick changes via pallets/recipes — all the way to integration into automated laser cells.

If you are currently labeling a lot of articles and your recording is becoming a bottleneck, talk to us — we will be happy to discuss which setup method (manual or programmable) best suits your process.

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